Greenheck Fan 474753 User Manual

Part Number 474753

®

Grease Grabber™ Triple Play

Kitchen Exhaust Pollution Control System

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Grease Grabber™ Triple Play

The Greenheck Grease Grabber™ Triple Play is a preengineered mechanical ﬁltration pollution control unit with integral exhaust fan (available without exhaust fan as an option). The unit is designed to remove grease and smoke particles as well as odor molecules from the kitchen exhaust airstream. This installation manual covers procedures for receiving, installing, and maintaining the ﬁltered section of the unit.

For additional instructions and maintenance information on the integral exhaust fan, when applicable, refer to the fan nameplate to determine model type and visit www.greenheck.com to download the corresponding manual.

General Safety Information

Only qualiﬁed personnel should install this system. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

DANGER

Always disconnect power before working on or near a fan. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

When servicing the fan, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.

CAUTION

Precaution should be taken in explosive atmospheres.

• Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.

• The rotation of the fan wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.

• Fan motor must be securely and adequately grounded.

• Do not spin fan wheel faster than maximum cataloged fan rpm. Adjustments to fan speed signiﬁcantly effects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

• Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace cord immediately if damaged.

• Verify that the power source is compatible with the equipment.

• Never open access doors to a duct while the fan is running.

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Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the packing list ensuring all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and ﬁled with the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading. Filters are shipped on a separate skid in their original packaging. Do not remove factory packaging or install ﬁlters until just prior to commissioning. Remove all other shipping/ packing materials including fan tie down straps.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

INDOOR

The ideal environment for the storage of units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts allow cold parts to

reach room temperature. To dry parts and packages, use a portable electric heater to get rid of any moisture buildup. Leave coverings loose to permit air circulation and to allow for periodic inspection.

OUTDOOR

Units designed for outdoor applications may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The unit should be placed on a level surface to prevent water from leaking into it. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.

Do not cover parts with plastic ﬁlm or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

Inspection and Maintenance during Storage

While in storage, inspect fans once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to ﬁfteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

Removing from Storage

As units are removed from storage to be installed in their ﬁnal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation. Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base, and accessories for tightness.

2. Rotate the fan wheel(s), where applicable, by hand and assure no parts are rubbing.

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Table of Contents

Installation .................................4

Rigging/Placing Equipment ..................4

Duct Connections .........................4

Electrical Connections ......................4

Fire System ..............................5

Filter Installation ...........................5

Operation ..................................5

Start-Up .................................5

Filter Status Indicator ......................5

Filter Replacement .........................6

Carbon Panel Replacement .................6

Maintenance ...............................6

Regular Scheduled Maintenance .............6

Replacement Filter/Parts Ordering ............6

Figures #1 and #2 ...........................7

Wiring Diagram ........................... 8-9

Maintenance Log ........................ 10-11

Warranty ..................................12

Filter stages 1, 2 and 3 are mechanical air ﬁlters of progressive ﬁltration efﬁciency that retain the smoke and grease particles.

Each ﬁlter stage is monitored by an individual pressure switch that signals when a particular ﬁlter stage needs replacing. The pressure switches are located inside the Pressure Switch Enclosure located on the access door side of Triple Play housing, between ﬁlter stages 2 and 3. When a ﬁlter stage requires replacement, a signal from the pressure switch lights an LED located on the remote mounted Filter Status Indicator. This enclosure must be ﬁeld mounted in an area convenient for monitoring by the cook staff.

System Components

Cabinet Assembly

The unit body is shipped on a common mounting rail ready for installation. If the unit was ordered with an exhaust fan, the fan will also be mounted as part of the cabinet assembly.

Filters

Filter quantity for each ﬁlter stage is based on unit size. A consistent quantity of ﬁlters is provided for each stage of ﬁltration (pre-ﬁlter, bag ﬁlter, and rigid ﬁnal ﬁlter). Quantity of carbon panels will vary based upon unit exhaust rate.

Grease Grabber Triple Play System Function

Grease Grabber Triple Play is a 3-stage mechanical air ﬁltration unit, with an additional carbon ﬁlter module, designed for two speciﬁc functions:

• Remove smoke/grease particulate from kitchen exhaust.

• Remove odor molecules from kitchen exhaust.

NOTE

Grease Grabber Triple Play must be connected to a listed exhaust hood assembly and must be installed in accordance with local building codes, NFPA 96 and NEC.

NOTE

Grease Grabber Triple Play is not intended for use with solid fuel cooking appliances.

NOTE

The unit must be installed with a minimum 18 inch clearance to combustible materials and must be installed as part of a listed duct assembly.

Unit Size Filter Quantity (each)

10-10 1

10-20 2

10-30 3

20-20 4

20-30 6

20-40 8

30-30 9

30-40 12

40-40 16

40-50 20

Remote Status Indicator (See Page 6) At time of delivery, a remote status indicator is

mounted within the rigid ﬁlter section of the unit body. This item must be removed and mounted remotely in the cooking area prior to unit start-up.

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Installation

Rigging/Placing Equipment (See Figure #1)

1. The unit is furnished with lifting lugs at the four corners and along the length as necessary.

2. Lift into place using all the lifting lugs.

3. Field weight will vary depending upon ﬁnal selections such as fan type, accessories, etc. Approximate weights are shown in the table below.

Unit Size

Approximate

Weight (lbs)

Approximate

Weight (kg)

Duct Connections

Ductwork must conform to the IMC and SMACNA guidelines.

As speciﬁed in NFPA 96, Ch. 7.5 (latest edition), exhaust duct systems must be constructed in the following manner; unless otherwise speciﬁed by the local authority having jurisdiction (AHJ):

Materials

Ducts shall be constructed of and supported by carbon steel not less than 1.37 mm (0.054 in.) (No. 16 MSG) in thickness or stainless steel not less than

1.09 mm (0.043 in.) (No. 18 MSG) in thickness.

10-10 1100 500

10-20 1600 727

10-30 2150 977

20-20 2600 1182

20-30 3500 1591

20-40 4200 1909

30-30 4700 2136

30-40 5700 2591

40-40 7300 3318

40-50 8000 3636

4. The unit can be positioned on a base or curb suitable for this purpose.

5. The unit must be anchored to its base/curb.

6. Alternatively, the unit may be suspended from an adequate overhead structure, using suitable undercarriage or hanging rods (by others). If the unit is suspended by hanging rods, minimum 1/2 inch (12.7 mm) diameter threaded rod is to be used. All hanger brackets/lifting lugs must be used to ensure proper support of the unit. The unit must also be hung level to ensure proper operation.

7. A service clearance of 36 inches must be provided on the access door side of the unit.

8. A minimum 18-inch clearance must be maintained between this unit and any combustible material.

9. The remote Filter Status Indicator (See Page

6) should be located in an area convenient for monitoring by the cook staff. For details on wiring this item, refer to the Electrical Connections section on this page.

Installation

All seams, joints, penetrations, and duct to hood collar connections shall have a liquid-tight external weld.

An inlet transition is furnished to match the inlet duct size. The inlet transition is furnished with a listed duct access door for inspection and cleaning.

Units intended for indoor mounting are provided with a UL 762 listed exhaust fan with outlet mounting ﬂange. Outlet ductwork from the exhaust fan is required to be per the above mentioned methods unless otherwise speciﬁed by the local authority having jurisdiction (AHJ).

Electrical Connections

Electrical wiring must conform to the equipment data plate information and to the NEC and local code requirements.

Motor

This unit is furnished with a remote-mounted motor starter and an ON/OFF disconnect switch mounted adjacent to the fan and factory-wired to the fan motor.

A 3-phase electrical supply must be ﬁeld wired to the motor starter and from the motor starter to the ON/ OFF disconnect switch.

Refer to the applicable fan installation manual for detailed instructions on wiring the fan.

Remote Status Indicator

A single phase electrical supply must be ﬁeld wired to the pressure switch enclosure (located on the access side of the Triple Play housing between ﬁlter stages 2 and 3, adjacent to the exhaust fan). For wiring details, refer to the diagram on pages 8 and 9.

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Fire System

This equipment is furnished with factory pre-piped ﬁre suppression nozzles and fusible link detector brackets. The brand of the system was speciﬁed at time of order (Amerex or Ansul). Factory installation is according to the Fire System manufacturers recommendations. Field connection, tanks, controls, fusible link detectors, and commissioning is provided and installed, on site, by others. The AHJ may require additional protection.

Filter Installation (See Figure #2 on page 7)

All 4 stages of ﬁlters are shipped on a separate skid in the original factory packaging. Do not remove packaging or install ﬁlters until just prior to commissioning the unit.

Care must be taken to ensure ﬁlters are installed in the proper sequence and proper direction of airﬂow for ﬁlter stages 1, 2 & 3 (stage 4 carbon panels are not subject to airﬂow direction).

Open the access doors. Remove the ﬁlter compression plates at stages 1, 2, 3 & 4. Install ﬁlters and replace all 4 ﬁlter compression plates. Compression plates must be in place to ensure proper ﬁlter sealing integrity. Close and latch access doors.

NOTE

Access doors are on lift off hinges and can be easily removed for more convenient ﬁlter servicing.

Operation

NOTE

Prior to starting the fan, remove fan tie down straps. These are used only to prevent shipping damage. After removing the tie down straps, the fan should float freely on the spring isolators. Confirm that the installation is completed as shown in the Installation section.

Start-Up

Turn the unit on momentarily and then turn off. Remove fan drive access cover and verify proper fan wheel rotation. If rotation is backwards, reverse the fan motor electrical input leads. After verifying proper fan wheel rotation, the unit is ready for operation.

Filter Status Indicator

As ﬁlter stages 1, 2 and 3 load with smoke and grease particles, resistance to airﬂow increases and the exhaust air volume decreases. Pressure switches continuously read the resistance across each ﬁlter stage. Each pressure switch is factory preset to transmit an alarm signal when that stage of ﬁlter has reached its terminal resistance and needs replacing with new ﬁlters. This terminal resistance setting is based on the ﬁlter manufacturers rating. The alarm signal lights an LED located on the face panel of the remote Filter Status Indicator Enclosure.

Filter Stage

Pre-Filter

(Stage 1)

Bag Filter (Stage 2)

Rigid Filter (Stage 3)

Carbon Panel (Stage 4)

Only UL 900, Class 1 ﬁlters are approved for use in this equipment. Substitutions will void the manufacturer’s warranty and the listing to UL

710. Please refer to the Maintenance section for information on ordering replacement ﬁlters.

Dimensions (inches) Description

24 x 24 x 4 thick MERV 8 Pleated metal frame ﬁlter

24 x 24 x 22 deep MERV 14 Bag ﬁlter

24 x 24 x 12 thick MERV 16 95% DOP HEPA-type ﬁlter

24 x 24 x 1 thick Bonded carbon panel

NOTE

IMPORTANT

Replace ﬁlters immediately after the Filter Status Indicator light comes on. Failure to do so may cause a reduced exhaust air volume allowing smoke to escape into the kitchen, or may cause ﬁlters to rupture, or both. The terminal resistance for each stage of ﬁlters is factory set at the values shown below. Altering these settings without ﬁrst contacting Greenheck Fan Corp. will void the manufacturers warranty and void the UL 710 listing.

Filter Stage Resistance Setting

1 1.2 in. wg.

2 1.0 in. wg.

3 1.7 in. wg.

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Filter Replacement

REMOTE FILTER STATUS INDICATOR

STATUS INDICATOR

Determine which stage(s) of ﬁlter needs replacing as shown by lighted LED(s) located on the face panel of the remote Filter Status Indicator Enclosure.

1. Have the correct type and quantity of ﬁlters available at the unit.

2. Turn off and lockout power to the fan.

3. Open the appropriate access door(s) and remove the ﬁlter pressure plate(s).

4. Remove the spent ﬁlter(s) by sliding them out of the housing access door opening.

5. Replace with the proper new ﬁlter(s) making sure

REMOTE FILTER

direction of airﬂow is correct.

6. Replace ﬁlter compression plate(s).

7. Close and latch access door(s).

8. Turn on power to the fan.

9. Proper ﬁlter disposal is important to the environment. Refer to local landﬁll codes.

CHANGE

PRE FILTER

R

CHANGE

BAG FILTER

R

CHANGE

RIGID FILTER

R

Maintenance

Regular Scheduled Maintenance

1. Replace stage 1, 2 and 3 ﬁlter(s) immediately after the remote Filter Status Indicator LED(s) light up.

2. Replace carbon panels at the ﬁrst sign of odor breakthrough.

3. Remove all ﬁlters and carbon panels and pressure wash/clean the housing interior yearly. Only use degreasers that are compatible with painted metal surfaces. Use caution so as to not damage static pressure tips, tubing or ﬁre system nozzles and detectors. Dry the housing interior and replace Stage 1-4 ﬁlters, replace ﬁlter pressure plates, close and latch access doors.

4. Remove/open fan scroll access door and pressure wash/clean all internal surfaces of the fan every 6 months. Check sheave-belt alignment and belt tightness.

Replacement Filter/Parts Ordering

Replacement ﬁlters and carbon panels can be obtained through any source offering UL 900, Class 1 ﬁlters as speciﬁed in the Filter section under Filter Installation. As a recommendation, replacement ﬁlters are available through AirScrubbers Inc.

Phone: 919-718-5818

www.airscrubbersinc.com

Carbon Panel Replacement

Unlike particulate ﬁlters, technology has yet to develop a cost-friendly method of determining when the carbon panels need replacing. So, the industry standard is the human sniff test. As the carbon begins to lose its effectiveness, odor breakthrough gradually occurs and odor concentration increases. Based on a variety of cooking applications/installations, life of the carbon panels can range from a few months to one year. Replace carbon panels when odor breakthrough is ﬁrst noticed. When replacing carbon panels, follow the instructions in the Operation section, Filter Replacement, Steps 2-10. There is no particular direction of airﬂow for carbon panels.

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Figures

Figure #1

INLET TRANSITION (OPTIONAL)

PRESSURE SWITCH ENCLOSURE

ACCESS DOOR

ON/OFF DISCONNECT

Figure #2

STAGE # 2 FILTER COMPRESSION PLATE

STAGE # 1 FILTER

COMPRESSION PLATE

STAGE # 1 FILTER

STAGE # 2 FILTER

PRESSURE SWITCH

ENCLOSURE

STAGE # 3 FILTER

STAGE # 4 FILTER

ACCESS DOOR SIDE

(Elevation View)

STAGE # 3 FILTER COMPRESSION PLATE

STAGE # 4 FILTER COMPRESSION PLATE

ACCESS DOORS REMOVED

(Elevation View)

ON/OFF DISCONNECT

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Wiring Diagram

132

134

136

F F

112M

FAN MOTOR

208-230/460V, 60HZ, 3PH

1725 RPM

INPUT POWER

208-230/460V, 60HZ, 3PH

F F F F

DISCONNECT SWITCH CIRCUIT BREAKER

100 DISC

__ A

MCB

1101

1121

1141

F

1102T21122

T1

130CR1

130CR2

L1

F

STEPDOWN TRANSFORMER

PRIMARY FUSE

ON/OFF MOTOR

DISCONNECT SWITCH

F

1142

T3

130CR3

122 T

FAN VOLTAGE

1102

1142

50VA

H4

H3

H2

H1

L2

L3

0.5A

120FU-2

0.5A

120FU-1

X1

X3 X2 XF

SECONDARY FUSE

115 VAC

1143

124FU 0.6A

1262

INDICATOR LIGHT

PRIMARY POWER

1262

G

128 LT

1301

FAN CONTROL

2TB1

1262

130CR

X1 X2

1302

130CR4

1TB4

1301

13011261

C

110, 112, 114, 126

2TB2

A2

A1

96

95

1TB5

COMBINATION MOTOR

STARTER DISCONNECT

106

108

100

102

104

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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110

112

114

116

118

120

122

124

1261

126

130 SW

128

OFF

ON

1301

130

1TB2

XOO 43

1TB1

HIGH PRESSURE LIGHT

PRE FILTER

BAG FILTER

HIGH PRESSURE LIGHT

RIGID FILTER

4TB-1

1262

3TB-4

1361

SERIES ADPS-03-2-N

ADJUSTABLE DIFFERENTIAL

136DPS

3 2

(COM) (NO)

1261

3TB-1

4TB-2

1262

3TB-5

1401

PRESSURE SWITCH

(NC)

READ ACROSS PREFILTER

1

SERIES ADPS-05-2-N

2

140DPS

3

1261

3TB-2

4TB-3

1262

3TB-6

1441

READ ACROSS BAG FILTER

PRESSURE SWITCH

ADJUSTABLE DIFFERENTIAL

1

(NO)

(NC)

144DPS

(COM)

1261

3TB-3

SERIES ADPS-05-2-N

ADJUSTABLE DIFFERENTIAL

READ ACROSS RIGID FILTER

PRESSURE SWITCH

1

(NC)

(NO)

3 2

(COM)

R

136PL

F F

PRESSURE SWITCH ENCLOSURE

(located on access door side of Grease Grabber Triple Play housing)

X2

X1

R

140PL

F F

X1 X2

R

144PL

F F

X2

X1

LOCATE IN KITCHEN AREA

REMOTE FILTER STATUS INDICATOR

132

F F

134

136

138

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Maintenance Log

Date __________________ Time _____________ AM/PM Notes:___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Date __________________ Time _____________ AM/PM Notes:___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________

Grease Grabber Triple Play Kitchen Exhaust Pollution Control System

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Warranty

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the shipment date. Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.

As a result of our commitment to continuous improvement, Greenheck reserves the right to change speciﬁcations without notice.

Greenheck Grease Grabber Triple Play catalog provides additional information describing the equipment, fan performance, available accessories, and speciﬁcation data.

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information. This publication can be obtained from AMCA International, Inc. at: www.amca.org.

®

Phone:(715)359-6171•Fax:(715)355-2399•E-mail:gfcinfo@greenheck.com•Website: www.greenheck.com

12

Greenheck Fan 474753 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual